Clutch master cylinder

Essential special tooling
Tool 1596	24 mm socket for removal and refitting of accelerometer

Tightening torques
battery cover screws (left-hand drive)	0.4 daN.m
clutch pedal bracket nuts	2.1 daN.m
battery cover screws (right-hand drive)	0.4 daN.m

REMOVAL

• Disconnect the battery, starting with the negative terminal.
• Remove:

• the engine covers,
• the battery,
• the battery tray.

• Disconnect the injection ECU.
• Remove the injection ECU.

• Loosen the air hose clamp (1).
• Remove:

• the air sleeves (2),
• the air filter housing.

• Drain the brake fluid reservoir until the level is below the master cylinder supply port.

JH3 or JR5

• Lift the clip (3).
• Pull the clutch control pipe out by one notch.

ND0

• Press the clip (4) by hand while pulling on the pipe.

WARNING

Do not pull on the clip. Any handling error requires replacing the pipe.

• Pull the clutch control pipe out by one notch.
• Place a rag under the bleed port.
• Operate the pedal by hand (to empty the master cylinder and the pipe).

LEFT-HAND DRIVE

• Place a rag under the port (5).
• Disconnect the pipe from the brake fluid reservoir.
• Fit plugs to the openings.
• Place a rag under the master cylinder.
• Remove the connector clip from the master cylinder (6).
• Disconnect the pipe.
• Fit plugs to each port.
• Disconnect the master cylinder pushrod from the clutch pedal in the passenger compartment.

• Remove the bulkhead master cylinder in the engine compartment by turning it a quarter turn clockwise (bayonet fixing) using tool (Emb. 1596).

RIGHT-HAND DRIVE

Note: The clutch master cylinder is mounted on the clutch pedal. Remove the pedal-master cylinder assembly to extract the pedal and the master cylinder.

• Drain the brake fluid reservoir until the level is below the master cylinder supply port using a syringe.

• Remove the grey (9) travel start switch by turning it a quarter turn.
• Disconnect the connector of switch (9).
• Remove the green (10) end-of-travel switch by turning it a quarter turn.
• Disconnect the connector of switch (10).
• Place a rag under the master cylinder.
• Remove the connector clips from the master cylinder (11).
• Disconnect the pipes.
• Fit plugs to the openings.
• Remove the clutch master cylinder pushrod from the pedal.
• Remove the four nuts from the "pedal" assembly.
• Remove the "pedal - master cylinder" assembly.
• Remove the bulkhead master cylinder by turning it a quarter turn clockwise (bayonet fixing) using tool (Emb. 1596).

INSTALLATION

LEFT-HAND DRIVE

• Check the condition of the seals.
• Refit in the reverse order of removal.

Note:

• Lubricate both ends of the supply line with brake fluid to ease fitting onto the brake fluid reservoir outlet.
• The transmitter has a polarising key, so there is only one possible position.

WARNING: Do not use the outlet as a support when fitting.

• Connect the transmitter ball joint to the clutch pedal.
• Pull the end of the sensor fully to position it at minimum.

The pedal position sensor has automatic adjustment that adapts to the pedal position.

• Refit in the reverse order of removal.
• Bleed the clutch control (see Chapter Mechanical Controls, Bleeding the Clutch Circuit, page 37A-39).
• Check that the clutch system operates correctly.

WARNING

Connect the battery; carry out the necessary relearn procedures (Chapter Battery).

• Tighten the battery cover screws to torque (left-hand thread) (0.4 daN.m).

RIGHT-HAND DRIVE

• Check the condition of the seals.
• Refit in the reverse order of removal.
• Tighten the clutch pedal bracket nuts to torque (2.1 daN.m).
• Pull the end of the sensor fully to position it at maximum.

The pedal position sensor has automatic adjustment that adapts to the pedal position.

• Refit in the reverse order of removal.

• Position the switches in their housings and turn them one quarter turn clockwise.
• Reconnect the two clutch pedal switches.
• Bleed the clutch control (see Chapter Mechanical Controls, Bleeding the Clutch Circuit, page 37A-39).
• Check that the clutch system operates correctly.

WARNING

Connect the battery; carry out the necessary relearn procedures (Chapter Battery).

• Tighten the battery cover screws to torque (right-hand thread) (0.4 daN.m).